Using a spark plug wire crimping tool involves preparing the wire, fitting the connector, and using the tool's jaws to secure the terminal to the wire's core and insulation.
Here's a breakdown of the process to create a properly crimped spark plug wire end:
Essential Steps for Crimping Spark Plug Wires
Before you begin crimping, ensure you have the correct spark plug wire, terminals (often included in spark plug wire kits), and the appropriate crimping tool. Different terminals and tools may have specific instructions, so always consult the manufacturer's guide if available.
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Prepare the Wire:
- Measure and cut the spark plug wire to the desired length using a dedicated wire cutter.
- Carefully strip back the outer insulation and the dielectric core around the conductor wire at the end where you will attach the terminal. The amount stripped depends on the terminal type, but typically it's just enough to expose the conductor wire and leave a small section of the insulation for the tool to grip.
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Insert the Terminal:
- Slide the metal terminal (the connector that will attach to the spark plug or distributor/coil) onto the prepared end of the wire. The conductor wire should align with the terminal's inner crimping area, and the stripped insulation should sit under the terminal's outer crimping area.
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Position in the Crimping Tool:
- Open the spark plug wire crimping tool.
- Place the terminal, with the wire inserted, into the correct crimping jaws on the tool. Many tools have different sections for crimping the core/conductor and the insulation simultaneously or in separate steps. Ensure the terminal is seated correctly within the tool's jaws according to its design. It's important to "Check my tool once again make sure everything's good," as seen in the reference, ensuring the wire and terminal are properly aligned before proceeding.
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Perform the Crimp:
- Firmly squeeze the handles of the crimping tool together. The tool's jaws will press down on the terminal, deforming it to secure the conductor wire and grip the wire's insulation. Apply even pressure until the tool completes its cycle or the handles meet, depending on the tool type. As described in the reference, you can then "crimp away boom there it is we got ourselves a really nicely crimped spark plug wire."
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Inspect the Crimp:
- Release the tool's handles and remove the crimped wire end.
- Inspect the crimp to ensure it is secure. The terminal should be firmly attached to both the wire conductor and the insulation. Give it a gentle tug to confirm it won't pull off easily. A proper crimp is crucial for good electrical connection and longevity.
By following these steps and using the correct tool, you can create reliable spark plug wire connections.
